Abstract:
This study presents the development and validation of a high-fidelity finite element model for crashworthiness analysis of full-sized vehicles, focusing on the 1997 Ford Crown Victoria. The model was created to evaluate the crash safety of various vehicle types and assess the potential impact of lightweight vehicles in the automotive fleet.
The modeling process involved a detailed vehicle tear-down, digitization of structural components using FaroArm 3D measurement technology, and material property testing. The finite element mesh was generated using TrueGrid, ensuring geometric accuracy for major structural components. The model was then validated against full-scale frontal and side impact crash tests conducted under the New Car Assessment Program (NCAP). Additional validation was performed using component-level impact tests, including bumper and door rigid pole tests and vehicle frame rigid wall tests.
Simulation results demonstrated strong correlation with experimental crash data, accurately capturing force histories, structural deformations, and energy dissipation patterns. The study highlights the importance of detailed mesh analysis and contact modeling to enhance crash simulation accuracy. The validated model provides a critical tool for assessing vehicle crashworthiness, occupant protection, and the effects of new automotive design trends.
Future refinements will focus on enhancing multi-layer structural characterization, improving material modeling, and expanding the framework to analyze additional impact conditions, including oblique and rear-end collisions. This research underscores the necessity of high-fidelity finite element models in advancing vehicle safety assessment and regulatory compliance.
